Centrifugal dirt separation configurations for household-type and shop-type vacuum cleaners

ABSTRACT

A cyclonic separation device in accordance with an embodiment of the present application preferably includes a first cyclone chamber having a cylindrical shape with a predetermined diameter, the first cyclone chamber including, a tangential inlet positioned on a first longitudinal end of the first cyclone chamber, a baffle plate positioned in the first cyclone chamber a predetermined distance from the tangential inlet, a tangential dirt outlet positioned on a second end of the cyclone chamber, opposite the inlet and on an opposite side of the baffle plate from the tangential inlet and a center exit duct mounted in the center of the cyclone chamber having an inlet opening positioned upstream from the baffle plate such the centrifuged fluid without particles flows into the center exit duct and out of the cyclone chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. nonprovisionalapplication Ser. No. 12/074,438 filed Mar. 8, 2008 entitled CENTRIFUGALDIRT SEPARATION CONFIGURATIONS FOR HOUSEHOLD-TYPE AND SHOP-TYPE VACUUMCLEANERS which claims benefit of and priority to U.S. Provisional PatentApplication Ser. No. 60/892,723 filed Mar. 2, 2007 entitled CENTRIFUGALDIRT SEPARATION CONFIGURATIONS FOR HOUSEHOLD-TYPE AND SHOP-TYPE VACUUMCLEANERS, the entire contents of which are hereby incorporated byreference herein.

BACKGROUND

1. Field of the Disclosure

The present application relates to an apparatus for separating dirt ordust particles from an air flow by cyclonic means. The applicationrelates particularly, but not exclusively, to a cyclonic dust separationapparatus for use in a vacuum cleaner.

2. Related Art

Cyclone dust separation devices typically include a frustoconical(truncated cone) cyclone having a tangential air inlet at the one endhaving a large diameter and a cone opening leading to a dirt or dustcollection area at the other end which has a smaller diameter.

There are numerous patents describing a variety of bagless vacuumcleaners now on the market by manufacturers such as Dyson, Hoover,Bissell; i.e. U.S. Pat. Nos. 5,858,038; 5,062,870; 5,090,976; 5,145,499;6,261,330 and 5,853, 440; English Patent Pub. No. GB727137; and FrenchPatent Pub. No. FR1077243.

U.S. Pat. No. 6,261,330 discloses a device including a fan for causingfluid to flow through the cyclone separator, the cyclone separatorhaving an inlet and an interior wall having a frusto-conical portiontapering away from the inlet, wherein the fan is positioned in the inletto the cyclone separator chamber on the same axis thereof, such thatfluid passing through the fan is accelerated towards the interior wall,and thereby, given sufficient tangential velocity to cause cyclonicseparation of particles from the fluid flow within the cyclonicseparator chamber. The fan motor is located on the centerline of thecyclone separator chamber, and thus, adds to the size of the cycloneseparator chamber.

In U.S. Pat. No. 6,261,330, the inlet port arrangement and theconcentric exit port connectors to the cyclone separator are notoptimum. The cyclone chamber depends on gravity to keep the dirt in thebottom of the collection chamber, thus requiring the suggested alternateconfiguration in which the motor is connected to the fan by a long shaftthat extends through the cyclone chamber to the fan at the top of thechamber. This position is not ideal for providing suction to lift dirtfrom the floor. The patent contends that this is an advantageous designbecause it lowers the center of gravity of the device as a whole whencompared to the embodiment shown with the motor at the top of thevertical cyclone separation chamber.

Since many standard vacuum cleaner motors now run at very high RPM's(22,000 RPM, for example) they provide good airflow and vacuumperformance with reduced weight. Having a long shaft through the cycloneseparator chamber, however, as suggested by the referenced patent, wouldnot be ideal since shaft critical speed vibration problems are likely toresult, thus preventing any weight reduction options to improve thedesirability of the vacuum cleaner for the public use.

All of the cyclonic separator type vacuum cleaners now on the markethave their cyclone separator chamber on the suction side of the fan sothat they are driven by the air flow that is being sucked through them.This has the advantage of only clean air being pulled through the fanimpeller, but provides much less velocity and energy than would beavailable by placing the cyclone separation chamber on the dischargeside of the vacuum fan.

Accordingly, it would be desirable to provide a cyclonic dust separationdevice, preferably suitable for use in a home vacuum cleaner that avoidsthe problems discussed above.

SUMMARY

It is an object of the present invention to provide an apparatus forseparating particles from a fluid flow having a cyclone separator whichis efficient, compact, lightweight, and easy to service and maintain.

A cyclonic separation device in accordance with an embodiment of thepresent application preferably includes a first cyclone chamber having acylindrical shape with a predetermined diameter, the first cyclonechamber including, a tangential inlet positioned on a first longitudinalend of the first cyclone chamber, a baffle plate positioned in the firstcyclone chamber a predetermined distance from the tangential inlet, atangential dirt outlet positioned on a second end of the cyclonechamber, opposite the inlet and on an opposite side of the baffle platefrom the tangential inlet and a center exit duct mounted in the centerof the cyclone chamber having an inlet opening positioned upstream fromthe baffle plate such the centrifuged fluid without particles flows intothe center exit duct and out of the cyclone chamber.

The cyclonic separation device of the present application may be used ina variety of applications, including, but limited to use in centrifugalseparation type vacuum cleaners.

A vacuum cleaner in accordance with an embodiment of the presentinvention preferably includes a handle and a floor housing to which thehandle is pivotally connected. The floor housing preferably includes asuction fan motor, a suction fan driven by the motor and including aplurality of fan blades driven at a high velocity by the suction fanmotor to suck a fluid from a first side of the fan to the second side ofthe fan, a pick up head positioned adjacent to a floor and in fluidcommunication with the suction fan and a cyclonic separator device. Thecyclonic separator device includes a first cyclone chamber having acylindrical shape with a predetermined diameter, the first cyclonechamber including a tangential inlet positioned on a first longitudinalend of the first cyclone chamber, a baffle plate positioned in the firstcyclone chamber a predetermined distance from the tangential inlet, atangential dirt outlet positioned on a second end of the cyclonechamber, opposite the inlet and on an opposite side of the baffle platefrom the tangential inlet; and a center exit duct mounted in the centerof the first cyclone chamber having an inlet opening positioned upstreamfrom the baffle plate such the centrifuged fluid without particles flowsinto the center exit duct and out of the first cyclone chamber, whereinthe pick up head and suction fan are connected in fluid communicationwith the first cyclone chamber such that fluid flows from the pick uphead through the tangential inlet into the first cyclone chamber androtates therein at high velocity such that particles in the fluid areforced out to the inner surface of an outer wall of the first cyclonechamber and beyond the baffle plate to be discharged through the dirtdischarge outlet.

A vacuum cleaner in accordance with another embodiment of the presentinvention preferably includes a handle and a floor housing to which thehandle is pivotally attached, The floor housing preferably includes asuction fan motor, a suction fan, driven by the motor, a first cycloneseparator connected to an inlet of the suction fan. The first cycloneseparator preferably includes a first cyclone chamber having acylindrical shape with a predetermined diameter, the cyclone chamberincluding a tangential inlet positioned on a first longitudinal end ofthe first cyclone chamber, a baffle plate positioned in the chamber apredetermined distance from the tangential inlet, a tangential dirtoutlet positioned on a second end of the cyclone chamber, opposite theinlet and downstream of the baffle plate, a center exit duct mounted inthe center of the cyclone chamber having an inlet opening positioneddownstream from the baffle and in fluid communication with the suctionfan inlet such that rotation of the suction fan draws fluid into thefirst cyclone chamber to rotate at high velocity forcing particles inthe fluid past the baffle plate and out of the tangential dirt outletand a removable dirt collector in fluid communication with thetangential dirt outlet and structured to store the particles dischargedfrom the tangential dirt outlet.

Other features and advantages of the present invention will becomeapparent from the following description of the invention which refers tothe accompanying drawings

BRIEF DESCRIPTION OF THE DRAWING(S)

FIG. 1 illustrates an upright floor sweeper vacuum cleaner in accordancewith an embodiment of the present application

FIG. 2 shows a top view of the vacuum cleaner described for FIG. 1.

FIG. 3 shows a front view of the conceptual configuration of FIG. 1.

FIG. 4 shows a cross sectional side view of the upright floor sweeper ofFIG. 1.

FIG. 5 shows a schematic type top view of the vacuum shown in FIG. 4.

FIG. 6 shows a perspective schematic type view of a basic pressuredriven cyclone separator for use with the vacuum cleaner of FIG. 1.

FIG. 7 shows a schematic type side view of a basic pressure drivencompact cyclone separator for use with the vacuum cleaner of FIG. 1.

FIG. 8a shows a partial cross sectional perspective flow drawing of abank of small diameter cyclone separators for a secondary separator foruse with the vacuum cleaner of FIG. 1.

FIG. 8b is a top view schematic of FIG. 8a.

FIG. 9 shows a cross section of a floor sweeper upright type vacuumincluding the secondary separator of FIG. 8.

FIG. 10a illustrates an alternative embodiment of a vacuum cleaner inaccordance with the present invention.

FIG. 10b illustrates another alternative embodiment of a vacuum cleanerin accordance with the present invention.

FIG. 11a shows the vacuum cleaner of FIG. 10a with a bottom dirtcollector removed.

FIG. 11b shows the vacuum cleaner of FIG. 10b with a bottom dirtcollector removed.

FIG. 12 shows an alternative embodiment of a primary cyclone separatorof the vacuum cleaner of FIG. 1.

FIG. 13 shows a side view of an embodiment of a primary cycloneseparator for the vacuum cleaner of FIG. 1.

FIG. 14a shows an alternate configuration of the vacuum cleaner of FIG.10.

FIG. 14b shows the vacuum cleaner of FIG. 14a with the dirt bag removedand the retention spring rolled back.

FIG. 15 is an exemplary illustration of a HEPA type very small particlefilter for use with the vacuum cleaner of the present application.

FIG. 16 illustrates another exemplary embodiment of a vacuum cleaner inaccordance with the present application.

FIG. 17 shows a bottom view of the vacuum cleaner of FIG. 16 without abottom cover.

FIG. 18 shows an external view of the bottom of the vacuum cleaner ofFIG. 17 with the bottom cover in place.

FIG. 19 shows cross sectional side view of the vacuum cleaner of FIGS.16-18.

FIG. 20 shows a more detailed view of the primary cyclone separator ofthe vacuum cleaner of FIGS. 16-19.

FIG. 21 shows an alternative embodiment of the primary cyclone separatorof FIG. 20.

FIG. 22 shows a secondary cyclone separator suitable for use in thevacuum cleaner of FIG. 16.

FIG. 23 illustrates a vacuum cleaner in accordance with anotherembodiment of the present application.

FIG. 24 shows an illustration of a high performance cyclone separator ofthe concept illustrated in FIG. 6 applied to replace a cleanable filtercloth in a central vacuum system in accordance with an embodiment of thepresent invention.

DETAILED DESCRIPTION OF EMBODIMENTS

The theory of cyclone dirt or dust separation suggests that efficiencycan be increased by increasing the tangential velocity of the air in theseparation chamber. This would typically suggest providing a morepowerful motor to create a higher rate of fluid flow. However, there arelimits to the size and weight of motors that the market will toleratefor domestic vacuum chambers, since the size and weight of thesechambers naturally influences the size and weight of the resultingdomestic home vacuum cleaner as a whole. Increased complexity and sizealso add to the cost of the vacuum cleaner, which is also an importantconsideration in the competitive home vacuum cleaner market.

Thus, reducing the size of the motor required to provide a simple highefficiency domestic home vacuum cleaner or shop vacuum cleaner is verydesirable. Smaller, lighter weight, more energy efficient vacuumcleaners provide significant advantages in such a competitive market.The vacuum cleaner of the present application allows for a reduction inmotor size in that it preferably provides the dirt separation chamber onthe output, or blowing, side of the suction fan, which allows thesuction fan to impart more speed to the dirt laden air as it is providedto the separation chamber. Thus, higher speed air is provided in theseparation chamber without the need to use a larger motor. In addition,the diameter of the separation chamber may also be reduced, which alsoaids in maintaining high velocity air flow therein and provides betterseparation while reducing overall vacuum size. These features aredescribed in further detail below.

In the vacuum cleaner 1 (See FIG. 1), for example, of the presentapplication, the design of the fan motor and fan can be separatelyoptimized while maintaining proper motor cooling. Further, the vacuumcleaner of the present application is preferably buildable usingexisting highly developed domestic vacuum cleaner motors now inproduction. In addition, the incoming flow to the fan impeller does nothave to be compromised and the cyclonic separating chamber can beoptimized separately without the need to compromise its design for motoror fan considerations, as is the case in the prior art discussed above.

The design of the present application minimizes the opportunities forflow passage blockage that is a problem in other cyclone dirt separationvacuum cleaners now on the market since all of the air flow elements arepreferably close connected with minimum duct work and high velocity air.This reduces the opportunity for velocity and pressure drops as airflows through the cleaner.

FIG. 1 illustrates a conceptual perspective view of an upright typevacuum floor cleaner 1 in accordance with an embodiment of the presentapplication. The cleaner 1 includes a handle assembly 4 which can bepivotally mounted to the side of the vacuum cleaner housing assembly 5which is partially carried by rear wheel assembly 7 and whose pick uphead 9 rides in close proximity to a carpet or floor. The head area 9preferably includes small rollers (not shown) mounted under the housing5 as well.

The vacuum cleaner suction fan and motor assembly 20 generates suctionthat is connected to the head area 9 of the vacuum cleaner 1. Thesuction lifts dirt and dust from the floor and into the vacuum 1. Thisdirt-laden air then passes through the motor driven fan 6 (See FIG. 4)and is accelerated by the high velocity of the fan rotor blades 8. In apreferred embodiment, the velocity of the blades 8 may be almost thespeed of sound (1100 ft/sec) such that the air and dirt is thrownthrough the tangential input connecting duct 11 to the primary cycloneseparator 22. The primary cyclone separator 22 preferably includes arelatively small diameter cyclone chamber 10 (preferably approximately 4inches in diameter) where the dirt is moved against the outside walls bythe very high centrifugal forces and passes the baffled plate 12 (SeeFIGS. 6 and 7) to be discharged tangentially from the chamber 10 throughtangential dirt outlet 23 into a dirt collection bag or container 14.

The dirt free air, however, moves towards the center of the cyclonechamber 10 and exits through a central duct 16 where it can then befinally filtered by filter 18, if desired, or run through a secondarycyclone separator 65 which preferably includes a group of small diametercyclone chambers 60 which generate very high g-forces due to theirsmaller diameter.

It is preferred that the air velocity remain high and that thecomponents of the cleaner 1 are closely coupled together to provide forminimum pressure drop between components and to maintain a very openflow design.

The secondary cyclone separator 65 is shown in more detail in FIGS. 8aand 8b, and is preferably embodied as a group of small diametertangential entry chambers 60 on top of truncated cones 62 that taper toa decreased radius for increasing centrifugal force and includingtruncated opening 63 at the bottom thereof to provide for dirt dischargeinto a separate, very fine dirt collection chamber 64. This chamber 64can also be separately cleaned less often than the larger dirtcollection chamber 14. The dirt exit, or openings 63 of each of thesmall truncated cones 62 can have a reverse cone shape to spread thespinning dirt outwardly and allow more separation between the discardeddirt and the returning air circulation at this location. Air preferablyenters the chambers 60 via the inlets 61

The primary, first, cyclone chamber 10 removes all of the larger dirtand a large part of the smaller dirt because of its high velocity,before the air is discharged into these small diameter chambers 60through connecting duct openings which allow them to operate at maximumefficiency. Thus, the primary cyclone chamber 10 effectively deals withthe larger, more voluminous dirt by discharging it into a largecollection container 14 which can be several times the capacity of thelow efficiency cyclone first stage chamber of bagless vacuum cleanersnow on the market since they have to capture the large dirt in the lowerpart of their cyclone chamber and provide sufficient space toaccommodate dirt storage and cyclonic separation. In contrast, in thecleaner 1, for example, of the present application, the dirt isdischarged tangentially from the primary cyclone chamber into a separatecontainer for dirt storage. Thus, the size of the primary cyclonechamber is reduced and this provides improved efficiency. Dirt storagecan be increased as well, since a separate chamber is provided for theseparated dirt, this chamber can be rather large which allows thechamber to be emptied less often. It is noted that the dirt collectionchamber 14 is preferably removably attached to the cleaner 1 to allow itto be easily removed and emptied.

The secondary cyclone section 65 has high efficiency and includes aplurality of small diameter cyclone chambers 60 which are left tofunction in their optimum condition with comparatively clean air, i.e.air only including particles with a diameter of 50 microns.

The air can then be withdrawn centrally from each of the second stagehigh efficiency cyclones chambers 60 via the ducts 70 and exhausted, ifdesired, through exit duct 80 to HEPA filter 18, if desired. Howeversome, or most of this air may alternatively be returned to the vacuumpick up head 9 through the opening 13 to provide jet assisted suction atthe pick up area (FIG. 9). The opening 13 is preferably positioned todischarge the returned air substantially parallel to the floor, creatingan area of low pressure just above the floor due to the high velocity ofthe returned air. This area of low pressure (i.e. Bernoulli pressure)aids in suction at the pick up head 9. The return air is in turn suckedback into the vacuum 1 again where the cycle is repeated. In thismanner, the air sucked into the cleaner 1 can be recycled to aid infurther suction and separation.

The primary cyclone separation chamber 10 provided in the cleaner 1 ofthe present application preferably has a relatively small diameter (4inches, for example) which is quite small when compared to that requiredwhen the dirt is being separated on the suction side of the vacuum fan,as in the prior art discussed above. This allows for a much morecompact, lighter weight and lower manufacturing cost vacuum cleaner.Also, the configuration of the cleaner 1 ensures that the dirt is notcaptured at the bottom of the primary cyclone chamber, but is dischargedtangentially into a bag or dirt compartment 14 separated from thecyclone chamber 10. This, as previously stated, also allows for areduction of the size of the cyclone separation chamber and moreversatility to allow the cyclone dirt separation chamber to be used in avariety of vacuum cleaners configurations including shop vacuums orcanister type vacuums, as well as carpet sweeper uprights such as thatillustrated in FIG. 1.

The vacuum cleaner design of the present application also has manyadvantages over prior art vacuum cleaners that use disposable porousbags which must be purchased separately and require frequentreplacement. These bag-type vacuums lose effectiveness as the filterbags becoming full and fine particles become trapped by the filter bagto degrade its permeability and cause a loss of suction. While vacuumcleaners using cyclonic separation chambers are known in the art andavoid the problems of replaceable bag cleaners discussed above, thesecyclone separation vacuum cleaners are very large, since they mustaccommodate the larger separation chambers necessary to provideseparation and dirt storage.

One of the important features of the vacuum cleaner described herein isto provide for open air flow and to separate the dirt from the air byintense centrifugal force cyclone action such that filtration is only afinal back-up if necessary at all.

In a preferred embodiment, the vacuum cleaner 1 of the presentapplication preferably includes a pick up head 9 with a power drivencarpet brush 3 (See FIG. 4). The suction fan and motor assembly 20preferably includes an electric motor and impeller, impeller inlet andfan 6 with a tangential discharge outlet that is aligned with thetangential inlet 11 of the primary cyclone separation chamber 10 whichhas cylindrical walls. The dirt collection chamber 14 may be embodied asa simple non-porous bag or a separate chamber and is connected to atangential outlet 23 of the chamber 10. A back up filter 18 may beprovided as well, if desired. A secondary cyclone separator 65 may alsobe provided in the discharge flow path of the primary separator chamber10. This secondary separator 65 is preferably optimized to remove fineparticles from the air.

Referring to FIG. 2 which is a top view looking down on the vacuumhousing assembly 5 of the cleaner 1 of FIG. 1, the air flow path fromthe dirt pick up head 9 through the suction fan and motor assembly 20and into the primary cyclone dirt separator chamber 10 can be seen.

FIG. 3 shows a front view of the cleaner 1 of FIG. 1. FIG. 4 shows across sectional side view of the upright floor sweeper cleaner 1 of FIG.1 showing the direct tangential close coupled connection between thesuction motor and fan rotor assembly 20 and the tangential inlet 11 tothe cyclone separator chamber 10 along with the brush 3 (add to FIG. 4).The brush 3 may be driven by a belt connected to the fan 6 or motorshaft (not shown). FIG. 5 shows a schematic type top view of the vacuumshown in FIG. 4. FIG. 6 shows a perspective schematic type view of theprimary cyclone chamber 10 for use with the vacuum cleaner of FIG. 1. Inparticular, FIG. 6 illustrates the exit duct 16 which allows cleaned airto exit the chamber 10. It is noted that the separation chamber 10 ofFIG. 6, for example may be used in a variety of applications includingvarious vacuum cleaner configurations with the same benefits. FIG. 7shows a schematic type front view of the primary cyclone separatorchamber 10 with tangential inlet 11 and dirt outlet 23 and with thecentral air exit passage 16 with inlet 24. The baffle plate 12 separatesthe tangential dirt discharge area proximate the outlet 23 from therecirculation area of the chamber 10.

FIG. 12 illustrates an alternative embodiment of the primary cycloneseparation section 22 in which the center central air exit duct 16include an inlet 24, as illustrated in FIG. 7 covered by a perforatedcylinder including a plurality of small diameter holes 25 (i.e.0.076-0.2 inches) rather than being fully open. The holes 25 providenoise isolation and prevent any large dirt or fluff from carpet beingdischarged from the chamber 10 during any periods of pressurefluctuation, i.e. momentary pressure fluctuations when the vacuum movesfrom a carpet to a bar floor.

In operation, the dirt-laden air enters tangential inlet 11 as shown bythe airflow lines 11a. The dirt is moved to the outer walls of thechamber 10 by the centrifugal force resulting from the high velocity ofthe inlet dirty air and the relatively small diameter of the chamber 10.The centrifugal dirt separation force may be determined based on thefollowing equation:F=w/gv²/rwhere “F” represent the centrifugal force, “w” represents the weightflow, g is a gravitational constant, “v” is the velocity of the air and“r” is the inside radius of the chamber 10. The dirt particles move downthe chamber 10 and pass the baffle plate 12 to be discharged from thechamber 10 at high velocity out of tangential outlet 23. The outlet 23is preferably connected to the collection chamber 14, or to a bag tocollect the dirt. The lighter air that accompanies the dirt into thechamber 14 is recirculated back as is illustrated by the line 23c ofFIG. 12 and into the chamber, or swirl area 27 downstream of the baffle12 and recirculated in this area. The air flow exits the cycloneseparator chamber through the holes 25 in the duct 16. This exit air isvery clean due to the high centrifugal force in the chamber 10, whichseparates particles form the airflow. Only the clean air near the centerof the chamber 10 is allowed to exit.

FIG. 13 shows a side view of the primary cyclone separator chamber 10with an additional perforated liner duct, or insert, 17 inserted intothe duct 16 to provide sound (noise) dampening. The duct 17 is designedto provide a Helmholtz resonator effect due to its hole sizes and cavityspacing behind the liner walls to reduce the noise emitted from thecleaner 1, for example.

FIG. 10a shows a conceptual perspective view of a canister type or shopvacuum cleaner 100 in accordance with another embodiment of the presentapplication. The cleaner 100 preferably includes a top cover and frame102 on which the basic vacuum cleaner elements may be mounted,including, suction fan motor and fan assembly 120, centrifugal separator122, and final filter 108. A vacuum hose (not shown) may be attached tothe suction fan inlet 110. Further, there is preferably a carryinghandle 125 provided along with a lower dirt collecting housing 114.

FIG. 11a illustrates cleaner 100 of FIG. 10a without the dirt collectinghousing 114 such that the mounting of the basic components 120, 122,118/108 can be seen as well as the tangential inlet 111 to thecentrifugal separator 122 and the suction fan tangential discharge port116 as well as the tangential dirt discharge port 23 of the centrifugalseparator 122.

In FIG. 10b, the suction fan inlet 110 is shown connected to the insidetop area of 120 of the primary dirt collection chamber 114a where theinlet 110b to the vacuum cleaner 100b is moved to enter the primary dirtcollection chamber 114a. This positioning allows nails or other largeitems of debris commonly cleaned using a shop vacuum to be collectedbefore the air passes through the fan. In addition, if the vacuum 100bis used to pick up water, for example, the majority of the water will betrapped in the main container 114a before complete separation isachieved by the primary cyclone separation chamber. Thus, the collectorchamber preferably includes low pressure side 114a and a fan dischargepressure side 114b that collects dirt or water separated from thesuction air and discharged from the separator 122 out tangentialdischarge outlet 123 into the chamber 114b.

The design of FIG. 10b represents a much improved shop vacuum (or wetpick-up shop vacuum) which typically only clean air with a washablesponge or cloth filter such that the discharged air is often very dusty.Similarly, when liquid is picked up, the discharge air tends to be verywet since the filter is saturated by water still in the air that ispassing through the discharge opening.

FIG. 11b shows the under side of the vacuum top assembly of FIG. 10bwith the container 114 removes. The motor and suction fan inlet 110 isnow relocated inside the vacuum cover 120 to provide suction by inlet110 directly into the container portion 114a.

FIG. 14a illustrates an alternate configuration of the vacuum cleaner100 of FIG. 10a with a non-porous plastic or paper bag 86 attached tothe cyclone chamber's tangential discharge 123. The throw away bag 86 ispreferably held in place with a roll spring 85 which can be rolled overthe bag opening to clamp it to the tangential dirt discharge duct. FIG.14b shows the vacuum cleaner 100 with the dirt bag 86 removed and theretention spring 85 rolled back to expose slot 87 which is preferablyformed on the outlet 123 to accommodate the spring 85 to keep the bag 86in place. The shop vacuum cleaner of FIGS. 10b and 11b may also utilizea bag as well to collect discharge dirt, if desired. The bag may bepositioned in, or in place of the chamber 114b, if desired

FIG. 15 is a partial sectional view of the HEPA type very small particlefilter 18 that is shown on the upright floor sweeper vacuum cleaner 1 ofFIG. 1, or on the alternative embodiment of FIG. 22, discussed below.The filter 18 preferably receives air discharged from the secondarycyclone separator 65 in FIG. 1, or to the air discharge duct of theprimary or secondary separator sections of the embodiment of FIG. 22.The filter 18 provides for final air filtration if desired. The filter18 preferably includes a housing 84 and an inlet 82 into which thecleaner air from the primary and secondary cyclone separation sections22, 65 pass for final filtering.

FIG. 16 illustrates a compact, light weight cyclone (centrifugal) dirtseparator, bagless re-circulated air and sound suppressed vacuum cleaner200 in accordance with an embodiment of the present application. Thevacuum cleaner 200 preferably includes a suction fan drive motor 220,fan 206, a large dirt centrifugal separator section 222 connected to thesuction fan inlet 217 and a large collection chamber 214, where all ofthese components are mounted in the floor housing 201. See also FIG. 17

A handle 205 is preferably pivotally attached to the housing 201. Asecondary cyclone separator section 260 is preferably mounted on thehandle 205, which is at least partially hollow to allow air to flow fromhousing 201 to the separator 264. A second removable dirt collector 265is provided with the secondary separator 264 which is for very fine dirtand need only be cleaned periodically. In addition, a HEPA filter 284may also be provide to provide additional final filtering, if desired,as shown in FIG. 22.

FIG. 17 shows an internal perspective view of the housing 201 with abottom cover removed such that the major components are visible. Asillustrated, the primary cyclone separator section 222 is mountedadjacent to the suction fan motor and housing 220. The fan 206 rotatesto create suction and pull dirt and air from the pick up head area 209through the tangential inlet 211 and into the cyclone chamber 219 of theseparator 222. The dirt rotates in the chamber 210 at high velocity andmoves to the inner surface of the outer walls of the chamber and pastthe baffle 212 into the discharge area 227 from which it is dischargedthrough tangential outlet 223 into the removable large dirt collector orbag 214 shown in FIG. 16. A belt 218 is preferably connected to a shaftof the motor or fan and is used to rotate brush 215 in the pick up headarea 209 to help lift dirt off the floor. An exit duct 216 is positionedin the chamber 219 to allow the cleaned air to exit the chamber throughthe holes 225 formed in a wall therein. The duct 216 is connected to thefan inlet at 217. Element 227 refers to the dirt swirl section, orcollection section, of the chamber 219 which is downstream of the baffle212 and includes the tangential dirt discharge outlet 223 for the dirtto be blown into the removable large dirt container 214. Anotheradvantage of discharging the dirt from the cyclone chamber is that thelarge dirt collection chamber or bag can take any desired shape tomaximize dirt volume storage efficiency.

The suction fan 206 air is discharged into the hollow handle mounting204 with some or most of it being provided to the collection duct 270for connection to a jet assist slot 271 (See FIG. 18) in the bottomcover 205. Jet assisted suction is discussed above with reference to thevacuum cleaner 1 of FIGS. 1-9, for example. Generally, the high velocityair produces a low-pressure area just above the carpet or floor due tothe Bernoulli effect.

FIG. 18 shows a bottom view of the vacuum cleaner 200 of FIG. 17 withthe bottom cover replaced. In addition, a recirculation air jet assistslot 271 around the suction pick-up opening 209 is shown with therotating floor brush 215.

FIG. 19 illustrates a cross sectional view of the housing 201illustrating how a portion of the cleaned air from the chamber 10 can beredirected to the jet assist slot 271 of the head area 209 while otherair is directed up the hollow handle portion 204 to the secondaryseparator 265.

FIG. 20 is a schematic view of the centrifugal dirt separator section222 and suction fan 206. As illustrated, the exit air duct 216 of thechamber 210 is connected to the inlet of the fan 206. FIG. 20 alsoillustrates the relationship of the tangential inlet 211 of the chamber210 and the tangential dirt outlet 223 as well as the openings 225 thatare preferably formed to provide an inlet for the exit duct 216 to allowthe cleaned air to escape chamber 222. The suction fan 206 is shownattached to the centrifugal separator exit duct 216 so as to providenoise isolation from the intake of the vacuum cleaner 200 near thesuction head area 209

FIG. 21 is an improvement on the features illustrated in FIG. 20. Inthis embodiment, a second insert 280 provided in the air exit duct 216to provide Helmholtz dampening of sound. This absorbs the high velocityfan blade and high velocity air noise from coming back out the inlet211.

FIG. 22 illustrates the secondary cyclone separator 260 mounted on thehandle 205 of the cleaner 200. The separator 264 is optimized forseparating very small particles from the cleaned air provided from theprimary separator 222. The separator chamber 264 thus includes aplurality of small diameter chambers 290 similar to the chambers 60described above with reference to FIGS. 8a and 8b. The chambers includesmall tangential inlets and tapered walls but are arrange around thehandle 204. Slots are provided in the handle 205 to correspond to theseinlet slots. The cup 265 is provided for dirt collection and ispreferably removable. In one embodiment a disposable bag may be placedinto the cup 265 to collect dirt.

FIG. 23 illustrates an alternative embodiment of a vacuum cleaner 300where the primary cyclone separator 322 is mounted on hollow handle 308and the larger dirt and much of the very small dirt is deposited into anon-porous bag or container 314. The container 314 may be made larger inthis embodiment since it is not part of the floor assembly. Secondarycyclone separation is provided in the separator 360, which may alsoinclude a HEPA filter, if desired. The first and second separators 322,360 however are similar to those described above with reference tovacuum 200.

FIG. 24 shows the application of the disclosed cyclone separatorillustrated in FIGS. 6 and 12, for example, in place of the cleanablefilter 403 commonly used in central vacuum systems. Generally, inconventional systems such as system 400 dirt is sucked into a removablecontainer 414 as shown in FIG. 24, so it can be discarded. However, theair is typically filtered by a cloth bag or other cleanable filter (seeelement 403, for example) which is dusty to clean and reducesperformance of the system as it gets clogged with dirt and dust.

In accordance with the present application, the central vacuum 410 haselement 401 which represents a suction fan drive motor, and element 402representing the suction fan while the cyclone separator is identifiedas element 413 which can be used to replace the filter 403 in thehousing of a central vacuum cleaner 400. The inlet port 406 from thecentral home vacuum is connected to the house vacuum piping which isconnected to the tangential inlet of the separator 413. A center airdischarge duct similar to duct 16 of FIG. 6 is preferably connected tothe suction fan inlet 402 to allow the suction fan to draw air at highvelocity through the tangential inlet of the cyclone centrifugalseparator 413. The separated dirt is discharged out tangential discharge416 and drops into the container 414.

Although the present invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art. It ispreferred, therefore, that the present invention be limited not by thespecific disclosure herein, but only by the appended claims.

What is claimed is:
 1. A vacuum cleaner, comprising: a handle; and afloor housing to which the handle is pivotally connected, wherein thefloor housing further comprises: a suction fan motor; a suction fandriven by the suction fan motor and including a plurality of fan bladesdriven at a high velocity by the suction fan motor to suck a fluid froma first side of the fan to a second side of the fan; a pick up headpositioned adjacent to a floor and in fluid communication with thesuction fan; and a cyclonic separator device comprising: a cyclonechamber having a cylindrical shape with a predetermined diameter, thecyclone chamber further comprising: a tangential inlet duct positionedon a first longitudinal end of the cyclone chamber; an opening formed inan outer wall of the cyclone chamber at a second end of the cyclonechamber, opposite the inlet through which particles exit the cyclonechamber; and a center exit duct mounted substantially in the center ofthe cyclone chamber having an inlet opening positioned such thecentrifuged fluid without particles flows into the center exit duct andout of the cyclone chamber, wherein the pick up head and suction fan areconnected in fluid communication with the cyclone chamber such thatfluid flows from the pick up head through the tangential inlet into thecyclone chamber and rotates therein at high velocity such that particlesin the fluid are forced out to the inner surface of the outer wall ofthe cyclone chamber and are discharged through the opening.
 2. Thevacuum cleaner of claim 1, wherein the inlet of the center exit ductincludes a sleeve including a plurality of perforations formed therein,such that the perforations prevent particles from entering the inlet. 3.The vacuum cleaner of claim 1, further comprising a jet assist ductconnected between the center exit duct and the pick up head and a jetassist nozzle positioned on the pick up head and connected to the jetassist duct to provide a stream of high velocity air in a directionparallel to the floor to be cleaned to aid in sucking particles off thefloor and into the pick up head.
 4. The vacuum cleaner of claim 3further comprising a collection chamber in fluid communication with theopening and structured to store separated particles from the fluid. 5.The vacuum cleaner of claim 1, wherein the handle is pivotally connectedto the floor housing.
 6. A vacuum cleaner comprising: a handle: a floorhousing to which the handle is connected; the floor housing furthercomprises: a suction fan including a plurality of fan blades driven at ahigh velocity to suck a fluid from a first side of the fan to a secondside of the fan; a pick up head positioned adjacent to a floor and influid communication with the suction fan; and a cyclonic separatordevice positioned upstream of the suction fan and in fluid communicationtherewith, the pick up head and suction fan are connected in fluidcommunication with the cyclonic separator device such that fluid flowsfrom the pick up head into the cyclonic separator device where itrotates therein at high velocity such that particles in the fluid areforced outwardly to an inner surface of the cyclonic separator deviceand out a particle exit duct formed therein.
 7. The vacuum cleaner ofclaim 6, wherein the cyclonic separator device further comprises: anouter cylindrical wall including a tangential inlet duct positioned on afirst longitudinal end thereof and in fluid communication with the pickup head and a tangential particle exit duct positioned on a secondlongitudinal end thereof, opposite the first longitudinal end; an innercylindrical wall positioned inside of and coaxially with the outercylindrical wall, the inner cylindrical wall including: an annularbaffle element extending outward from the outer surface thereof andpositioned on a second end thereof between the tangential inlet duct andtangential particle outlet duct; and at least one opening formed in theinner cylindrical wall proximate to the annular baffle and between thetangential inlet duct and annular baffle through which fluid passes toexit the cyclonic separator device.
 8. The vacuum cleaner of claim 7,wherein the tangential particle exit duct is positioned between theannular baffle and an end wall of the cyclonic separator device.
 9. Thevacuum cleaner of claim 7, further comprising a particle collectionelement in fluid communication with the tangential particle exit duct tocollect particles.
 10. The vacuum cleaner of claim 9, wherein theparticle collection element is a nonporous bag.
 11. The vacuum cleanerof claim 7 wherein the inner cylindrical wall defines a central exittube in fluid communication with the suction fan through which fluidexits the cyclonic separator device.
 12. The vacuum cleaner of claim 7,wherein the annular baffle is axially spaced from the tangential inletduct such that the annular baffle directs fluid into the at least oneopening formed in the inner cylindrical wall.
 13. The vacuum cleaner ofclaim 6, further comprising a second cyclonic separation device in fluidcommunication with the suction fan and positioned downstream thereof.14. The vacuum cleaner of claim 13, wherein a lower portion of thehandle is hollow and provides fluid communication between the suctionfan and the second cyclonic separation device.
 15. The vacuum cleaner ofclaim 13, wherein the second cyclonic separation device comprises aplurality of small diameter conical chambers positioned around thehandle and extending substantially perpendicular to a direction of fluidflow, each small diameter conical chamber further comprising a smalltangential inlet structured to allow a portion of the fluid to entereach of the small cyclonic chambers, such that the fluid rotates withinthe small diameter conical chambers to separate out any addition fineparticles in the fluid.
 16. The vacuum cleaner of claim 15, wherein eachof the small diameter conical chambers further comprises an outlet portstructured to disperse the fine particles separated from the liquid. 17.The vacuum cleaner of claim 16, further comprising a second particlecollection chamber in fluid communication with the outlet port of eachof the small diameter conical chambers and structured to collectdispersed fine particles from the fluid that is discharged from theoutlet port.
 18. The vacuum cleaner of claim 15, wherein each of thesmall diameter conical chambers includes a duct structured to allowfluid to exit out of the second cyclonic separation device.
 19. Thevacuum cleaner of claim 18 further comprising a filter positionedbetween the exits of the second cyclonic separator device and operableto provide additional filtering to remove any additional particles fromthe fluid leaving the second cyclonic separating device.
 20. The vacuumcleaner of claim 6, further comprising a jet assist duct connectedbetween the cyclonic separation device and the pick up head and a jetassist nozzle positioned on the pick up head and connected to the jetassist duct to provide a stream of high velocity air in a directionparallel to the floor to be cleaned to aid in sucking particles off thefloor and add momentum to help carry dirt particles into the pick uphead.
 21. A vacuum cleaner comprising: a hollow handle; a floor housingto which the handle is attached, the floor housing further comprising: asuction fan motor; a suction fan, driven by the suction fan motor; afirst cyclone separator connected to an inlet of the suction fan;wherein the first cyclone separator including: a cyclone chamber havinga cylindrical shape with a predetermined diameter, the cyclone chamberfurther comprising: a tangential inlet positioned on a firstlongitudinal end of the cyclone chamber; a baffle plate positioned inthe cyclone chamber a predetermined distance from the tangential inlet;a tangential dirt outlet duct positioned on a second end of the cyclonechamber, opposite the inlet and downstream of the baffle plate, throughwhich dirt particles exit the cyclone chamber; and a center exit ductmounted substantially in a center of the cyclone chamber having an inletopening positioned downstream from the baffle and in fluid communicationwith the suction fan inlet such that rotation of the suction fan drawsfluid into the cyclone chamber to rotate at high velocity forcing dirtparticles in the fluid past the baffle plate and out of the tangentialdirt outlet duct; a removable dirt collector in fluid communication withthe tangential dirt outlet duct and structured to store the particlesdischarged from the tangential dirt outlet duct; and a secondary cycloneseparator mounted on the hollow handle in fluid communication with thecenter exit duct and operable to separate any remaining dirt particlesfrom the fluid provided from the center exit duct.